Folded Honeycomb Structure for Thin Broadband Sound Absorption
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Solution Overview
Problem
Existing honeycomb structures for sound absorption coatings face challenges in achieving optimal sound absorption across frequency ranges without increasing thickness, particularly for low frequencies, and the manufacturing process limits material choices due to plastic deformation during shaping.
Innovation Solution
A method of manufacturing a honeycomb structure by folding and assembling identical strips of material to form alternating cells and ducts, allowing for wider material and thickness options, and facilitating assembly by creating symmetrical fold lines and grooves that connect cells without causing plastic deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic deformation is used to shape material strips during manufacturing, then the honeycomb structure can be formed, but the choice of materials and thicknesses is limited
Solution Approach 1:
The invention changes the manufacturing parameter from plastic deformation to folding operations. This allows the same manufacturing process to work with a wider range of materials and thicknesses, as folding does not require the material to undergo permanent deformation like plastic deformation does.
Solution Approach 2:
Instead of deforming the material to create the honeycomb shape, the invention inverts the approach by folding pre-formed strips along predetermined lines. This reverses the traditional manufacturing sequence and enables greater material versatility.
2Object-affected harmful factors
If large-volume cells are used to absorb low frequencies, then sound absorption effectiveness improves, but the thickness of the honeycomb structure increases
Solution Approach 1:
The invention introduces a third dimension by creating alternating rows of cells that open in opposite directions. This three-dimensional alternating pattern allows sound waves to interact with cell structures of effective acoustic volume without requiring the coating itself to be thick, as the alternating configuration creates acoustic pathways that are more efficient than simple linear depth.
Solution Approach 2:
The folding process creates nested hierarchical structures where multiple fold levels generate complex three-dimensional cell configurations from flat strips. This nesting allows the creation of effective acoustic volumes within a compact thickness by utilizing multi-level folding patterns.
3Adaptability or versatility
If folding is used instead of plastic deformation, then material and thickness choices are expanded, but new manufacturing challenges arise
Solution Approach 1:
The manufacturing process is segmented into distinct folding operations along predetermined fold lines. By dividing the complex shaping task into sequential folding steps at specific locations, the process becomes more manageable and adaptable to different materials while maintaining consistency through standardized fold patterns.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the creation of a thin, effective sound absorption coating that can attenuate both high and low frequencies while expanding the material and thickness choices available for the strips, improving the assembly process and structural integrity.
Implementation Method 1
a porous layer in contact with a medium in which sound waves propagate
Implementation Method 2
a reflective layer
Data Source
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AI summary
The invention relates to a method for manufacturing a honeycomb structure (50) having first and second faces, rows of cells (54) each comprising, alternately, first cells (56) open towards the first face, second cells (58) open towards the second face, and third cells formed between each row of cells (54), each row of cells (54) comprising first and second strips of material joined together. According to the invention, the first and second strips of material are shaped by folding. Unlike plastic deformation, shaping by folding allows for a wider choice of materials and thicknesses for the first and second strips of material. The invention also relates to a honeycomb structure thus obtained and to a sound-absorbing coating comprising such a honeycomb structure.